Saddletree construction and method



Dec. 27, 1966 A. HESSLER 3,293,828

SADDLETREE CONSTRUCTION AND METHOD Filed April 21, 1965 5 Sheets5heet lINVENTOR.

HESS LE R ATTORNEY Dec. 27, 1966 A. HESSLER SADDLETREE CONSTRUCTION ANDMETHOD 5 Sheets-Sheet 2 Filed April 21, 1965 INVENTOR. HESSLER ALBERTATTORNEY Dec. 27, 1966 A. HESSLER SADDLETREE CONSTRUCTION AND METHOD 5Sheets-Sheet 5 Filed April 21, 1965 IN VENTOR.

HE SSLER ALBERT ATTORNEY United States Patent 3,293,828 SADDLETREECGNSTRUCTIQN AND METHGD Albert Hessler, 3985 Cook St., Denver, Colo.802il5 Filed Apr. 21, 1965, Ser- No. 449,803 7 Claims. (Cl. 5444) Thepresent invention relates to saddletrees and to the manufacture andproduction of saddletrees from fiber glass.

Though the form and appearance of saddles has evolved over a long periodof years, saddles have predominantly been made of leather that is formedand shaped over a saddletree which provides the rigidity and strengthrequired in usage. In recent years saddletrees of wood have evolved intoa customary shape in which two spaced apart longitudinal members knownas tree rails or side bars are joined at the rear and front by cantleand saddle bow or pommel members. The saddletrees have usually beenformed from wood by carving and routing and joining processes to deriveshapes that would best accommodate the leather construction of thesaddle.

The manufacture of saddletrees from wood is a relatively expensiveprocess, since it requires the formation of individual side bars,cantles and pommels with subsequent accurate joining of such members tomake up a combined structure. In the more expensive saddles the woodsaddletree elements are joined together by use of glues and cloth, andsubsequently these parts are reinforced by the application of rawhidewhich further binds and strengthens the assembled saddletree. Because ofthe fact that the side bars are spaced each from each in theirlongitudinal course in order to provide clearance for the withers of thehorse, the leather worker has previously had a considerable problem inbuilding up a suitable construction that would span this longitudinalgap and provide smooth support for the saddle plate upon which the ridersits. In general, the prior construction method has been concerned withthe gradual build up of multiple layers of leather with each of thelayers of usually coarse grade material being carved or skived at theedges so that the termination of the separate layers will not bediscernible when the final saddle leather is in place. In more recentyears it has been recognized that some materials other than leather canbe adapted to this gap spanning function. Sheet metal and, finally,plastic or fiber glass components have been provided and used for thispurpose.

After a review of the known and existing techniques in the manufactureof saddletrees, the present inventor determined to provide a new andimproved saddletree which would be of such construction as to facilitatethe easier placement and support for the covering saddle leathers. Asthe result of such determination, the inventor now presents a saddletreeconstruction in which glass reinforced plastics materials are used toform an integral saddletree. Among the guiding objectives in theprovision of such improved tree are the following:

To provide a saddletree that is of final unitary construction in whichthe component segments mutually contribute to the strength of the entireassembly;

To provide a unitary saddletree of proper and smooth conformation sothat conventional saddle leathers, stirrups and skirts may beconveniently applied directly to the tree without the requirement forbuild-up support leathers;

To provide a saddletree which is initially formed of two major parts andin which such parts are joined together by simplified means to obtain astructurally strong and unitary construction;

To provide a saddletree, the elements of which will themselves span thelongitudinal slot between the side bars and provide smooth transitionsbetween saddletree parts so that saddle leathers can be applied directlyto the saddle tree;

To provide a saddletree construction, the elements of which may be madeup of two mating mold formed pieces notwithstanding the duplication ofthe characteristic obstr-ucting curves and convolutions of saddletreesand saddles;

To provide a saddletree construction that provides strong and securesupport for a saddle horn, and further to provide a modified saddletreeconstruction in which a saddle horn can be secured directly in moldedelements of the saddletree for integral bonding with the glass reinforced plastic components thereof.

Further objects and advantages of the present invention will be apparentfrom the description and drawings, in which:

FIG. 1 is a perspective view showing the overall saddletree constructionof a first embodiment of the invention,

FIG. 2 is a side perspective view showing further details of saddletreeconstruction,

FIG. 3 is a front elevation showing components of a mold formedsaddletree,

FIG. 4 is a cross-sectional elevation taken along the line 44 of FIG. 2,

FIG. 5 is a cross-sectional elevation taken along the line 5-5 of FIG.3,

FIG. 6 is a cross-sectional elevation taken along the line 6 6 of FIG.2,

FIG. 7 is a cross-sectional elevation taken along the line 7-7 of FIG.2,

FIG. 8 is :an exploded perspective drawing showing details of a secondembodiment of the invention, and

FIG. 9 is a perspective drawing of a saddle horn used in the secondembodiment of the invention.

Briefly stated, the present invention provides a saddletree made ofglass reinforced plastics materials, molded to provide thecharacteristic supporting structure of a saddletree and furtherincorporating additional design features contributing to the strength,utility and convenience of such saddletree. Significant aspects of theinvention are embodied in the fact that the new saddletree is molded inonly two separate pieces which are subsequently joined together alongmatching and mating external edges and internal surfaces during theforming process for the bottom piece in order to obtain an eventualstrong and unitary one-piece saddletree. With this construction allexposed surfaces are of smooth texture as derived from the mold surfacefor the component parts and necessary saddle leathers can be directlyapplied. The new and improved saddletree provides a hollow constructionof increased cross-sectional rigidity at points of maximum strain andbulk that is of significantly lighter weight than heretofore possible.The molding and fabricating process used to obtain the saddletree islikewise of significance inconnection with the practice of theinvention.

Two separate but related embodiments of the invention are shown in theaccompanying drawings. FIGURES 1 through 7 represent a first embodimentto which a saddle horn of existing type may be applied. The embodimentshown in FIGURES 8 and 9 includes the provision of a saddle horn whichis directly molded in the plastics materials of the top segment of thesaddletree to be tightly and securely held in such desired position whenthe plastics construction materials have cured. In most other respectsthe two constructions are similar, though some ditference inconfiguration for the pommel may be dis cerned that is representative ofthe type of changes that can be made in saddletree construction inaccordance with this invention to satisfy the use and appearancerequirements of individual purchasers and users.

In FIGURES 1 through 7 the unitary saddletree con struction isdesignated by the numeral 11. The major components of the unitary wholeinclude top and bottom segments 12 and 13 which are formed in separatemolds and which are joined together each to each during the formingprocess for the bottom segment by compressing the outer terminal edges14 and 17 of the top and bottom segments, respectively, together whilethe bottom segment 13 is being cured. In addition to the compressedjuncture at the outer terminal edges, the top and bottom segments arelikewise bonded together along the edges of the gullet 16 and along aconterminous joint section 18 extending rearwardly from the gullet to alocation ad jacent the cantle 19. The joint section 18 in generalapproximates the location of a gap previously existing between the sidebars of wood formed saddletrees.

Away from such section 18 and the terminal edges, the top and bottomsegments 12 and 13 are spaced each from each so that the final unitarysaddletree construction is hollow in positions corresponding to thecantle 19, the pommel 21 and the side bars 22. These points of hollowconstruction essentially coincide with the traditional positioning ofsolid wood members of a conventional saddletree. In the presentconstruction the hollow seg ments not only decrease the combined weightof the saddletree, but the hollow cross-section provides inherentreinforcing that duplicates the strength characteristics of the previoussolid wood components. For convenience of nomenclature, these hollowcomponents have been given names corresponding to those usually appliedin the description of saddletree construction. In the present instance,however, each of such components, other than the cantle, is made up inpart by .surfaces that are formed with the top segment 12 and in part bymatching or mating surfaces that are formed integrally with the bottomsegment 13.

The cantle construction itself is predominantly formed with the topsegment, but it should be noted that the bottom segment provides supportand reinforcement for the cantle by reason of the joinder along thejoint section 18 and further by reason of the junction between the backface 23 of the cantle 19 and the continuation of the bridge segment 24as seen in FIGURE 5. This bridge segment 24, in fact, continues fromthis rear point of junction just forward of the notch 26 behind thecantle 19 all the way forward to the pommel 21 and provides the lowermating edge at the gullet 16. At its front extent the bridge segment 24actually joins a yoke or saddle how 27 type of construction. The saddlebow 27 itself terminates in a front edge 29 which matches with a matingedge of the top segment pommel construction. The bottom segment yoke orsaddle bow 27 and the top segment pommel 21 together make up atransverse hollow section which tends to reinforce the saddletreeconstruction.

In similar manner the cantle 19 provides a strong transverse structurewhich adequately serves to hold the rear portions of what would be theside bars of a conventional saddletree together. As an improvement overconventional wooden saddletrees, the lower bridge segment 24 and the topsaddle plate 28, which includes the joint section 18, likewise furthersupports the unitary saddletree construction.

The unitary construction of the cantle, pommel and saddle plate 28represents a major improvement over previous saddletree construction,since it is possible with this new configuration to dispense with thepreviously necessary build-up leathers and separate support plates thatwere used to span the gap between conventional side bars. With the newsmooth contours for all surfaces the saddle plate leathers and, in fact,all other saddle leathers used in finishing a saddle may be directlyapplied to the saddletree.

The smooth surfaces and flared transitions used in the top segment,however, present a special mold problem that will be apparent afterconsideration of the divergent angular dispositions for the cantle andpommel. It will be seen that the swells 31 on the pommel 21 which arecharacteristic of Western type saddles extend in a direction oppositethe general direction for the cantle components. The swells 31 furtheroverhang the line of juncture 32 between the pommel and the saddle plate28 or the front portions of the side bars 22.

This angular positioning of components complicates the desiredattainment of a one piece top segment. Accordingly, special mold designsare necessary to obtain such desired construction. A two piece mold isused which has a match line that corresponds to the longitudinal axis ofthe top segment. After the unitary top segment has been molded, the moldcan then be parted along such match line so that the top segment can beextracted therefrom. Use of a conventional rigid type two piece moldwould make it possible to obtain a top segment of perhaps satisfactoryconfiguration, but it has been noted that the presence of desirablehollows on the front face of the cantle in the area 39 complicatesdirect extraction of molded segments from rigid molds. In order to avoidthese difficulties, the two piece mold for the top segment is itselfmade of flexible material so that the mold can be slightly deformed asthe top segments are extracted.

With the configurations illustrated it has been noted that the topsegments can best be extracted from the two piece flexible molds if themolds are sprung away from the pommel section first. Thereafter themolds can be pivoted about the line of juncture 33 between the rearcantle face 23 and the top surface of the side bar 22 so that the cantle19 can be loosened and extracted.

One further feature of the mold process is of major importance in theconstruction of glass fiber saddletrees in accordance with thisinvention. Since the top and bottom segments 12 and 13 are individuallyformed, it is necessary that they be joined together to provide thedesired unitary saddletree construction. For the purpose of securing astrong joint the mating edges 14 and 17 of the top and bottom segments12 and 13, respectively, are cooperatively formed so that a good bondmay be obtained along mating edge surfaces of considerable width. Inaddition to the mating edges 14 and 17, the top and bottom segments 12and 13 are provided with additional internal surfaces that mate each toeach. If a proper bond can be obtained between all of such cooperativemating surfaces, a strong and structurally rigid saddletree can beprovided.

While various types of adhesives and cements can be used to bond glassfiber pieces together, it has been found that a highly satisfactory bondcan be obtained through use of the glass fiber bonding resin itself.Since the polyester type resins normally used in the fabrication ofmolded glass reinforced plastics materials are considerably cheaper thanmost cements or adhesives that might be used, the use of such resins iseconomically advisable. While such resins may be used to join previouslyformed and cured pieces, it has been found that a further economy ispossible when the top and bottom segments are joined together at thesame time that one of such sections is itself being formed and cured.

Since the top segment is the more complicated piece, this segment isformed in its two piece mold and is allowed to cure to the point whereit can be removed from the mold. As a next step, the inception of whichmay begin coincident with the later curing cycle of the top segment, abottom segment is formed in its mold. The requisite layers of glassreinforcing and resin are applied until the desired thickness has beenobtained. Upon attainment of the required buildup and prior to thecomplete curing of the bottom segment, the top segment which has beenremoved from its mold is applied directly to the bottom segment while itis still in its mold and before the resin of the bottom segment hascured.

Clamping members are applied along the mating surfaces 14 and 17, andsimilar clamping frames are further applied along the bridge 24 andjoint section 18. With this arrangment the uncured resin of the bottomsegment will join and bond with the resins and materials of the topsegment. When the bottom segment has cured, a unitary saddletree can beremoved from the bottom segment mold, and the top and bottom segmentswill be found to be solidly and intimately joined each to each. Afterfinishing operations, which include the removal of overlapping glassfibers at the mold edges, the router cleanout of the gullet 16 and thelike, the completed unitary saddletree product is obtained.

For the embodiment shown in FIGURES 1 through 7, a saddle horn 37 may beapplied to the saddletree. To facilitate the installation, it ispreferred that a block of wood or other reinforcing block 36 be moldedinto the top segment 12 in position at the top of the pommel 21. Thisreinforcing block 36 will then provide strength and support for thesaddle horn 37 which can be applied to the external surface of the topsegment 12 by use of screws 38 or bolts which extend through the pommelsurface 21 and into the reinforcing block 36. The saddle horn 37 may beof a type providing holes 39 so that leather covers or otherornamentation may be applied to the horn 37.

In order to facilitate the application of stirrup straps, the bottomsegment itself is provided with strap receptacles 41. Such strapreceptacles include the provision of openings 42 through which thestirrup straps may be engaged and a raised section 43 on the top surfaceof the bottom segment 13, which is still spaced away from the topsegment 12 so that a strap may be engaged over such raised section 43and through the opening 42. The raised section 43 on the top surfaceprovides a corresponding channel 45 in the bottom surface of the bottomsegment to accommodate a return length or portion of such stirrup strap.A reinforcing bar 44 is preferably formed into the molded surface of thebottom segment 13 in position adjacent the opening 42 and at the top ofsuch raised portion 43 or the corresponding channel 45. This reinforcingbar 44 and the molded glass fiber which surrounds it provides a smoothcontour of a radius adequate to prevent undue wear or strain on thestirrup strap leathers.

In the embodiment shown in FIGURES 8 and 9, a modified construction isused so that the saddle horn 47 can be directly implaced in the topsegment 12 as such segment is being molded. Horn 47, as shown in FIGURE9, is provided with an elliptical base 48 which includes guide shoulders49 raised above the base. When the guide shoulders 49 are engaged incorresponding notches provided in the mold for the top segment 12, thesaddle horn 47 will be properly oriented with respect to the pommel 21and the other elements of the saddletree.

In the fabrication of this modified top segment, several layers of glassfabric and resin are first applied in the mold, and next the saddle horn47 is inserted through an opening in the mold, and clamping pressure isdirected against the base 48 of the saddle horn so that the guideshoulders 49 move into engagement with the corresponding guide notches.Thereafter, additional layers of glass fabric and resin are applied tothe top segment and about the base 48 of the horn 47 so that the base 48and the shoulders 49 will all be embedded directly in the reinforcedplastic structure of the top segment 12. With this direct embedmtent, itis found that a secure placement of the saddle horn is obtained.

This particular construction has an advantage over that of the firstembodiment, inasmuch as it has been found possible to provide a saddlehorn 47 that has a finished and polished exterior surface. The saddlehorn can, accordingly, be left exposed, and it is then only necessary toapply pre-cut saddle leathers to the pommel 21 in order to obtain afinished construction.

With any embodiment of the invention it is found that the application ofsaddle leathers is greatly expedited. The provision of a full seatconstruction and the further provision of smooth transition contoursbetween the seat, cantle and pommel make it possible to apply the finishsaddle leathers directly to the saddletree Without any requirement forthe cutting and fitting of buildup leathers. The bonded unitaryconstruction provides a strong saddletree which fully duplicates thestrength of side bar, cantle and pommel components of previous woodfabricated saddletrees. The hollow, spaced apart, cooperativeconfiguration for the top and bottom segments in areas corresponding tothe location of conventional saddletree side bars provides a strongrigid longitudinal support. A similar hollow construction for the cantleand pommel provides strong construction in the lateral directions.

A saddle horn that is applied externally as in the first embodiment orwhich is embedded in the molded plastic will be firmly supported by theyoke type construction for the pommel so that any forces exerted againstthe saddle horn will be efii-ciently transmitted to other portions ofthe saddletree. Actual tests of the strength of these molded fiber glasssaddletrees indicates that a strength equivalent to that of previousrawhide covered wood saddletrees may be obtained. The two piece bondedconstruction, accordingly, provides an improved type of saddletree whichcan be economically fabricated.

Inasmuch as further economies and advantages are noted when saddleleathers are applied to these accurately formed saddletrees, it shouldbe apparent that an overall improvement which is novel and useful ispresented by the present disclosure. Further, it should be noted thatthe improvement is in part embodied in the processes and methods used asWell as in the final construction of the saddletrees themselves.

Accordingly, while separate embodiments of the invention have been shownand described, it should be obvious that the invention is not limited tosuch specific embodiments or methods but is adaptable to variousmodifications and changes. All such modifications and changes that comewithin the scope of the appended claims are considered to be a part ofthis invention.

I claim:

1. A process for the manufacture of saddletrees in molded plasticsmaterials which comprises unitarily forming a top component of saidsaddletree having outermost contours characteristic of conventionalcantle and saddle bows inclusive of lateral overhanging projections in atwo part mold having a match line coinciding with the longitudinal axisof said saddletree, curing said plastics materials, removing said topcomponent from said top molds by parting the mold, forming a bottomcomponent of said saddletree having lower contours characteristic ofconventional side bar-stirrup supports in a one piece bottom mold,positioning said completed and cured top component in matching positionabove said formed and uncured bottom component, pressing said componentstogether, and allowing said bottom component to cure while in forcedcontact with the top component whereby said bottom and top componentswill be bonded together to provide a unitary hollow saddletreeconstruction.

2. A process for the manufacture of saddletrees from molded plasticsmaterials which comprises unitarily forming a top component of saidsaddletree inclusive of a cantle and saddle how each having lateralprojections in a two par-t mold having a match line coinciding with thelongitudinal axis of said saddletree, curing said plastics materials,removing said top component from said top molds by parting the mold,forming a bottom component of said saddletree inclusive of side bars andstirrup support pins in a one piece bottom mold, positioning saidcompleted and cured top component in matching posi- I tion above saiduncured bottom component, pressing said components together, andallowing said bottom component to cure while in forced contact with thetop component whereby said bottom and top components will be bondedtogether to provide a unitary hollow saddletree construction.

3. A process for the manufacture of saddletrees from molded plasticsmaterials which comprises unitarily forming a top component of saidsaddletree which is inclusive of cantle and pommel elements havingprojections disposed in opposed. directions by forming said topcomponent in a two part flexible mold which has a match line coincidingwith the longitudinal axis of said saddletree, curing said plasticsmaterials, removing said top component from said top part molds byparting and flexing said mold, forming a bottom component of saidsaddletree inclusive of side bars and stirrup support pins in a onepiece bottom mold, positioning said completed and cured top component inmatching position above said uncured bottom component, pressing saidcomponents together, and allowing said bottom component to cure while inforced contact with the top component whereby said bottom and topcomponents will be bonded together to provide a unitary hollowsaddletree construction.

4. A saddletree adapted for convenient use in the production of leathersaddles comprising a molded glass reinforced plastics constructioninclusive of individually mold formed top and bottom segments whereinsaid top segment is of a single sheet construction having thecharacteristic outermost contours and form of conventional saddle seatand overhanging cantle and pommel sections, said top segment beingformed unitarily to provide smooth transitions between said sectionswith full and direct support for all saddle leathers applied thereto,mating edge surfaces at the lateral extremities of said top segment,said bottom segment being of a single sheet construction and havingouter contours characteristic of the lower surfaces of the side bars ofconventional saddletrees, and mating edge surfaces at the lateralextremities of said bottom segment for engagement with the mating edgesurfaces of the top segment, said top and bottom segments being joinedtogether along said mating edge surfaces to provide a unitary hollowconstruction.

5. A saddletree adapted for convenient use in the production of leathersaddles when saddle leather cover pieces are applied to said saddletreecomprising a molded glass reinforced plastics construction inclusive ofindividually mold formed top and bottom segments wherein said topsegment is of a single sheet construction having the characteristicoutermost contours and form of conventional saddle seat and overhangingcantle and pommel sections, said top segment being formed unitarily toprovide smooth transitions between said sections with full and directsupport for all saddle leathers to be applied thereto, mating edgesurfaces at the lateral extremities of said top segment, said bottomsegment being of a single sheet construction and having outer contourscharacteristic of the lower surfaces of the side bars of conventionalsaddletrees, mating edge surfaces at the lateral extremities of saidbottom segment for engagement with the mating edge surfaces of the topsegment, and cooperative mating central surfaces disposed along thelongitudinal center line of said top and bottom segments, said top andbottom segments being joined together along said mating edge surfacesand along said centrally disposed surfaces to provide a unitary hollowconstruction at sections correspondvidually mold formed top and bottomsegments wherein said top segment is of a single sheet constructionhaving the characteristic outermost contours and form of conventionalsaddle seat and overhanging cantle and pommel sections, said top segmentbeing formed unitarily to provide smooth transitions between saidsections with full and direct support for all saddle leathers to beapplied thereto, a saddle horn disposed in position on the pommel ofsaid top segment, plastics materials molding said saddle horn in place,mating edge surfaces at the lateral extremities of said top segment,said bottom segment being of a single sheet construction and havingouter contours characteristic of the lower surfaces of the side bars ofconventional saddletrees, mating edge surfaces at the lateralextremities of said bottom segment for engagement with the mating edgesurfaces of the top segment, and cooperative mating central surfacesdisposed along the longitudinal center line of said top and bottomsegments, said top and bottom segments being joined together along saidmating edge surfaces and along said centrally disposed surfaces toprovide a unitary hollow construction at sections corresponding with thepommel, cantle and side bars of said saddletree.

7. A saddletree adapted for convenient use in the production of leathersaddles when saddle leather cover pieces are applied to said saddletreecomprising a molded glass reinforced plastics construction inclusive ofindividually mold formed top and bottom segments wherein said topsegment is of a single sheet construction having the characteristicoutermost contours and form of conventional saddle seat and overhangingcantle and pommel sections, said top segment being formed unitarily toprovide smooth transitions between said sections with full and directsupport for all saddle leathers to be applied thereto, said top segmentfurther providing a mating undersurface thereon, said bottom segmentbeing of single sheet construction and having outer contourscharacteristic of the lower surfaces of the side bars of conventionalsaddletrees, a mating upper surface on said bottom segment adapted forengagement with the mating undersurface of the top segment, said top andbottom segments being joined together along said mating surfaces toprovide a unitary hollow construction at sections corresponding with thepommel, cantle and side bars of said saddletree, and a saddle hornsupport element formed in said top segment.

References Cited by the Examiner UNITED STATES PATENTS 2,153,326 4/1939Crouter 54-44 2,451,651 10/1948 Baldwin 54-44 2,474,953 7/1949 Mock eta1. 54-46 2,624,167 1/1953 Diaz 54-46 2,871,014 1/1959 Benson 297-2,980,162 4/1961 Bourgols 297-195 3,088,259 5/1963 Nuzzo 54-44 3,112,59212/1963 Schindler 54-44 3,146,024 8/1964 Timms 297-195 3,153,887 10/1964Bohlin 54-37 3,157,976 11/1964 Ellsworth 54-44 ALDRICH F. MEDBERY,Acting Primary Examiner.

1. A PROCESS FOR THE MANUFACTURE OF SADDLETREES IN MOLDED PLASTICSMATERIALS WHICH COMPRISES UNITARILY FORMING A TOP COMPONENT OF SAIDSADDLETREE HAVING OUTERMOST CONTOURS CHARACTERISTIC OF CONVENTIONALCANTLE AND SADDLE BOWS INCLUSIVE TO LATERAL OVERHANGING PROJECTIONS IN ATWO PART MOLD HAVING A MATCH LINE COINCIDING WITH THE LONGITUDINAL AXISOF SAID SADDLETREE, CURING SAID PLASTICS MATERIALS, REMOVING SAID TOPCOMPONENT FROM SAID TOP MOLDS BY PARTING THE MOLD, FORMING A BOTTOMCOMPONENT OF SAID SADDLETREE HAVING LOWER CONTOURS CHARACTERISTIC OFCONVENTIONAL SIDE BAR-STIRRUP SUPPORTS IN A ONE PIECE BOTTOM MOLD,POSITIONING SAID COMPLETED AND CURED TOP COMPONENT IN MATCHING POSITIONABOVE SAID FORMED AND